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BASICS OF OIL ANALYSIS
The ack nowl edged l eader in o il a nal ysi s s ince 196 0
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BASICSOFOILANALYSIS
INTRODUCTION
Formany years, lubricant inspection and testing has been used to help diagnose the internal condition of oilwettedcomponentsandprovidevaluable informationabout lubricant serviceability.The first testmethodsused for thispurposeincludedsuchsimpleproceduresassmellingusedoilforthesourodorofexcessacid,checkingvisuallyforobvioussignsofcontamination, orplacingadropofsampleonabsorbentpapertodetectcontaminantsandmonitoradditiveeffectiveness.Asbasicresearchandtechnologyexpanded,progress in lubricant testingkeptpace.An increasingly largenumberof testsweredevelopedtoassesslubricantphysicalpropertiesanddetectcontaminants.
In1946theDenverandRioGrandeRailroadresearchlaboratorysuccessfullydetecteddieselengineproblemsthroughwearmetalanalysisofusedoils.Akeyfactorintheirsuccesswasthedevelopmentofthespectrograph,asingleinstrumentthatreplacedseveralwetchemicalmethodsfordetectingandmeasuring individualchemicalelementssuchas ironorcopper.Thispracticewassoonacceptedandusedextensivelythroughouttherailroadindustry.
By1955oil analysishadmatured to thepoint that theUnitedStatesNavalBureauofWeaponsbegan amajor researchprogramtoadoptwearmetalanalysisforuseinaircraftcomponentfailureprediction.Thesestudiesformedthebasisfora
JointOil
Analysis
Program
(JOAP)
involving
all
branches
of
the
U.S.
Armed
Forces.
The
JOAP
results
proved
conclusively
that
increases in componentwearcouldbeconfirmedbydetectingcorresponding increases in thewearmetalcontentof thelubricatingoil. In1958Pacific IntermountainExpress (P.l.E.)was the firsttruckingcompany tosetupan inhouseusedoilanalysislaboratorytocontrolvehiclemaintenancecosts. Thisextensivehistorymakesoilanalysistheoldestoftheproactivemaintenancetechnologies.
In1960Analysts,Inc.wasfounded,becomingthefirstindependentlaboratorytoprovideacompleteoilanalysisdiagnosticservicetoallareasofbusinessandindustry.
Ourmoderndayoilanalysisisbuiltonthefirmfoundationoftheseearlyefforts.Theimportanceofusingacombinationofphysicalandspectrochemicalteststomonitor lubricantandcomponentcondition isnowuniversallyaccepted.Oilanalysistestproceduresareestablishedandreviewedbysuchagenciesasthe InternationalOrganizationforStandardization(ISO),theAmericanSocietyforTestingandMaterials(ASTM)andtheSocietyofAutomotiveEngineers(SAE),andawidevarietyoflaboratoryandpersonnelcertificationshasemerged.
Analysts,Inc.
is
proud
of
our
major
continuing
role
in
the
original
and
current
development
of
commercial
oil
analysis
into
what isnowrecognizedasoneof themosteffectiveproactivemaintenance toolsavailable.We feelconfidentthattheoilanalysis instrumentsandtechniquesofthefuturewillbackourcontinuingcommitmenttoproactivemaintenance throughusedoilanalysis.
MarkSmith
TechnicalAdministrator
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 2 -
APPLYINGOILANALYSIS
Oilanalysisisthemostwidelyacceptedandimplementedformofproactivemaintenancetechnology.Itisanintegralpartofthe maintenance plan for power plants, manufacturing plants, trucking companies, construction equipment, aircraft,refrigeration systems, processing and chemical plants, etc. Any piece of equipment that has a lubricating system is an
excellentcandidate
for
oil
analysis.
A
successful
oil
analysis
program
requires
an
organized
and
sustained
effort.
Both
the
userandthelaboratorymustworkcloselytogethertoachievethedesiredresults.
OUTLINEFORANEFFECTIVEOILANALYSISPROGRAM
1. Determineyourprimaryobjectives.
Oilanalysiscanbeappliedtoequipmentutilization,maintenanceandmanagement:
Utilization
Increasemarginsofoperationalsafety
Increaseavailabilitybydecreasingdowntime
Increaseoverallcomponentlifespan
Controlstandbyequipmentandreplacementpartrequirements
Decreasefuelandoilconsumption
Maintenance
Identify
and
measure
lube
contamination
and
component
wear
Eliminateunnecessaryoverhaulsorinspections
Reduceinservicefailuresandfieldrepairs
Establishproperlubricantserviceintervals
Management
Improvecostassessmentandcontrolforequipment,laborandmaterials
Improveequipmentrecordkeepingprocedures
Evaluateequipmentdesigns/applications
Revealfaultyoperatorpractices
Almost anymachine that has a lubrication system can be placed on an oil analysis program. Those componentswhoseperformancedirectlyaffects the continuedoperationofaparticularunitoroverallprofitabilityofbusiness are themostlikelycandidatesforroutineoilanalysis.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 3 -
2. Carefullyconsideryourbestchoiceforoilanalysis
All oil analysis laboratories claim they are 'qualified',Although certifications and requirements that a 'qualified' used oilanalysislaboratorymustmeetarenowmuchmoredefinedthaninthepast,onethinghasnotchanged:You,theoilanalysisuser,mustchoosewhichlaboratorybestsatisfiesyourneeds.
Forexample,Analysts' five regional laboratorieshavebeen featured innumerousmagazinearticles,advertisements,andotherpublishedmaterials.These 'secondopinions'areexcellentsourcesofreferenceaboutourservice.Thebestguidetochoosingalaboratory,however, isexperience.Chancesare,someone inyourfield isalreadyusingoneormoreofthelabsyouareconsidering.Talkwiththem.They'llconfirmhowwedefine'qualified'.
Choose awellestablished laboratoryAnalysts, for example, has been in operation since 1960 long enough to havedevelopedcomplete,timetestedproceduresforanalysis,customercontactandsalesservice.Weofferawideselectionofsamplingmaterials, includingourpatentedBellows
,QSS
sampling valves,andother supplies andmake sure that these
materialsareinstockwhenyouneedthem.Weprovidetheadditionaldescriptiveliteratureandtrainingassistanceneededtosupportyouroilanalysisprogram.
Choose awellequipped laboratory Each Analysts' laboratory is deeply computerized, andmost of ourmodern,wellmaintainedinstrumentsareautomatedanddirectlyinterfacedwiththe labcomputersystem.Wefollowpublished,proventestingproceduresanduseonlythehighestqualitychemicals.Weencourageourcustomerstovisitourlabfacilities.
Choosea laboratorywithawelltrained,experiencedstaffAnalystsmarketingandtechnicalstaff'knowtheirbusiness'!MoreofourstaffmembersareSTLECertifiedLubricationSpecialistsorOilManagementAnalyststhananyothercommercialoilanalysis lab.Werecognizethespecifictechnicalrequirementsforyourapplicationandansweryourquestionsfully.Wehaveanorganizedapproachforestablishingyouasacustomerandcangiveyousound,practicalsuggestionsforovercominganyproblemsyoumightencounterinestablishingandmaintainingyourAnalysts'oilanalysisprogram.
Choose a laboratorywith a recognized quality control program Analysts, Inc. has one of the strongest certified andregistered ISO 17025 quality programs in commercial oil analysis. By attaining the ISO 17025 certification Analystsdemonstratesonadailybasisitscommitmenttoqualitydata,workandprocedures.Additionally,Analysts'qualityprogrammeetstherequirementsof10CFR50,AppendixBthefederalspecificationforqualityprogramsinnuclearpowerplants.Withourprogramofdocumentation, training,proceduresandfollowup,Analystsisrecognizedastheleaderinqualityandservicewithintheindustry.
Examine the reports for reliable recommendations and easy to read format Consistently accurate test results and
interpretationare
vital
to
the
success
of
your
oil
analysis
program.
Analysts'
report
forms
are
the
clearest
and
most
informative in the industry.Our recommendationsare specific,completeandeasy tounderstand.The recommendationsreflectarealknowledgeof theoperatingandwearcharacteristics foranycomponentsampled.Testresults indicating theneedforamajorinspectionaredoublecheckedpriortoyournotification.Manyofourstaffofdataevaluatorsandchemistsaremembersofprofessionalandtechnicalsocieties,andourestablishedpositioninthecommercialoilanalysisfieldensuresreadyaccesstolubricantandcomponentmanufacturers'data.
DemandrapidturnaroundofresultsandrecommendationsAnalystsmeetsandbeatsthefrequentlyadvertised24to48hour turnaround.Wewillnotifyyou immediately ifcriticalconditionsaredetected.Youcanobtain 'rush'handling ifyourequireanimmediateresponse,andafterhoursspecialopeningscanbearrangedincaseofemergency.
LookforspecializedsummaryreportsToassistourcustomerstomanageandcontroltheiroilsamplingprogram,wewillprovideanyofaseriesofeightspeciallydesignedprogrammanagementandsummaryreports.Thesereportsconsolidatesampling activity to compile the information such as Critical Condition Units, Condition Analysis Statistics, SummarizedSamplingActivityandSummarizedSampleConditions.Thereportsareavailableonamonthlybasis.
Lookforafullrangeof informationmanagementtoolsandoptionsAnalystsmaintainsacomprehensiveInternetsiteatwww.analystsinc.com. Analysisreportscanbereceivedviaemailattachmentdirectlyfromour laboratories.ThissitealsooffersacompleteWebbasedoilanalysismanagementsystem. ThroughourWindows basedoilanalysissoftwareprogramLOAMS (LubeOilAnalysisManagementSystem),yourentireoilanalysisprogramcanbemanagedoffline fromapersonalcomputer.LOAMSwilldownloadandstoreallsampledata,printreportslocally,graphsampledata,printsamplingschedulesbycomponentandallowtheexportingofdatatoothersoftwareprogramsforfurthermanipulation.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 4 -
3. Selectthepropertestsforyourapplication.
Differentcombinationsofphysicalandspectrochemicaltestsareusedtomeasurethepropertiesofthe lubricant itselfanddetermine levelsofcontaminantsandchemicalelementssuspended in the lubricant.Theapplicationandgoalsof theoilanalysisprogramhelpdeterminethenumberandtypeofteststhatshouldbeperformed.
Thephysical
analysis
concentrates
on
measuring
certain
physical
characteristics
of
the
lubricant.
These
tests
also
detect
and
measurecontaminantsandoilbreakdownbyproducts,aswellastheireffectonthelubricantproperties.
The spectrochemical analysis identifies andmeasures selectedmetallic elements present in the lubricant asmicroscopicparticles.Testresultsarereported inpartspermillion(ppm)byweight.Therelativeconcentrations oftheseelementsareusedtomonitorwearrates,detectcontaminantsanddetermineadditivelevels.
Analystshasdevelopedstandardized'packages'orcombinationsofroutinelyperformedtests.Thesepackagesaredesignedtocoverthegeneraltestingneedsofbroadserviceclassificationssuchasindustrial,construction,overtheroadtruckingoraviation.Sinceeachpackageconsistsofteststhatthe lab isalreadypreparedtoperform involume,significantsavingsarerealizedwhenapackageisselectedratherthanarandomgroupoftests.Additionalnonroutinetestscanbeperformedonrequest.Analystswillassistyouinselectingthepropercombinationoftestspriortobeginningyoursamplingprogram.
4. Determinethepropersamplingpointandmethod.
Obtainingarepresentativesampleisoneofthemostimportantpartsofascheduledoilanalysisprogram.Ifasampledoesnot represent the true conditionof the lubricantandcomponentat the timeof sampling, the reliabilityofboth the testresultsandtheirinterpretationisaffected.
Areaswherelubricantflowisrestrictedorwherecontaminantsandwearproductstendtosettleorcollectshouldbeavoidedassamplingpoints.Inspecialcases,samplesmaybetakenfromlubefilters.Thelabshouldbeadvisedifthisoccurs.
Werecommend thatyousampleacomponentwhile it isrunningorwithin30minutesaftershutdown.Thisensures thatwearproductsandlubricantcontaminantsarethoroughlymixedwiththelubricantandthattheheavierwearparticleshavenotsettledout.
Werecommendthefollowingsamplingpoints:
Apetcock
or
other
sampling
valve
installed
PRIOR
to
the
oil
filter
(using
Analysts'
QSS
valve)
Anoildipsticktubeorotherserviceopening(usingtheBellowsoravacuumpump)
Thesumporreservoirdrain
Onceapropersamplingpointandmethod ischosenforaparticularcomponent,oilsamplesfromthatcomponentshouldalwaysbetakenfromthesamepointwiththesamemethod.
5. Determinethepropersamplinginterval
Whenbeginning a routineoil analysisprogram, theusualpractice is to sample theentiregroupofunits/components toestablish initialbaselinedataandquicklyspotanycomponentswithseriousproblems.Once thisprocess iscomplete, thecustomer and laboratory then agree on an initial routine sampling interval. This interval is based on the results of thepreliminarysampling,componentmanufacturerguidelines,customermaintenanceproceduresandpersonnelschedulingandAnalysts'experiencewithsimilarcomponentsandapplications.Oncetheprogramisfullyestablished,theroutinesamplinginterval
may
be
adjusted.
Oncedetermined,routinesamplingintervalsshouldremainasconstantaspossible.
6. Establishconsistentoilanalysisbaselineinformation.
Inabusyoperationsandmaintenanceschedule,noonewantsextrapaperworkandrecordkeeping.But, ifanoilanalysisprogramistofurnishanythingmorethantestdata,theusermustprovideinformationontheequipment,componentsandlubricantsinservice.Onecommonfalseassumptionisthatanoilanalysislabcandrawvalidconclusionsfromthetestresultswithoutanysupportingdatafromthecustomer.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 5 -
Initialequipmentregistrationcanbeeasilyaccomplishedbyfurnishingthelaboratorywithaconsolidatedequipmentlist,orbycompletinganindividualregistrationformforeachsampledcompartment. Currentoperatingdataisthenforwardedwitheachsample.
Incompletingoilanalysisformsandsamplecontainerlabels,thefollowingbriefdefinitionsarehelpful:
UNIT l.D. NUMBER A unique reference number for an entire functional unit. Examples include an aircraftregistration
number,
company
asset
or
inventory
identification
or
avehicle
serial
number.
COMPONENT Theoveralltypeofoilwettedsystem,suchasengine,hydraulic,orgearbox,fromwhichthesampleistaken.Otherdesignationssuchasleft,number3,rearoranactualdescriptionofthecomponent'suse,suchasfandrive,winchorswingarealsoneededforclearidentification.
TIMESINCENEWORSINCELASTOVERHAUL Theoperatinghoursormilessincethesampledcompartmentwasfirstputintoservice,orsincethelastoverhaulorrebuildwasperformed.Sincenormalwearrateschangeoverthelifetime of a component and breakinmay resemble abnormalwear, this information is needed as an ongoingreferenceforinterpretation.Thisdatamaybeobtaineddirectlyfromanequipmentorcomponentservicemeter,orfromgeneraloperatingrecords.
TIME SINCEOILCHANGE Thenumber ofhoursormilesof componentuse between the time theoilwas lastchangedandthetimethesamplewastaken.Thisinformationisessentialtotimebasedtrending.
OILTYPE Themanufacturer,productname,andSAEor ISOviscositygradefortheoilthatwassampled.Sinceamanufacturermaysellmorethanoneblendofthesameviscosityproduct,thecompletenameisveryimportantindeterminingwhichtestingreferenceoilshouldbeused.
OILCONSUMPTIONorMAKEUPOIL Theamountofoiladded tomaintainacorrectoil fill level in thesampledcomponent.Completeoilchangesshouldnotbereportedasmakeupoiloridentifiedas'newoil'.
Asampleusuallycannotbeprocessed immediately if thecustomername,unitandcomponent identification,andsampledatearenotprovided. Ifyouhavesampledaparticularmachinebeforeanddonotensure that theunitandcomponentidentificationsmatchwhatyouoriginallyprovided, testingmaybedelayedor the resultsmaynotbe filed correctlywithothersamples from thatmachine. Inaddition to this "mustprovide"data foreachsample,youshould reportany recentmaintenance,changesinperformanceorunusualoperatingconditions.
Specificindividualsshouldbeassignedlongtermresponsibilityforthisportionoftheprogram.Ifthisisnotpossible,thena
particulardepartment
should
be
designated
for
involvement.
Once
this
responsibility
is
established,
asystem
of
record
keepingandcorrectsampleidentificationshouldbeinitiatedassoonaspossible.
7. Usethelabinterpretationofthetestdataproperly.
Our lab interpretationseparates theoverallcomponentand lubricantconditionand therelativeseverityofcontaminationandwearintofourmainclassifications:
Normal Physicalpropertiesofthelubricantarewithinacceptablelimits,andnosignsofexcessivecontaminationorweararepresent.
Monitor Specifictestresultsareoutsideacceptableranges,butarenotyetseriousenoughtoconfirmabnormalconditions. Caution is advised. The initial stages of an abnormality often show the same pattern of results astemporaryconditionssuchasextendedusageoroverloading.
Abnormal Lubricantphysicalproperties,contamination, and/orcomponentwearisclearlyunsatisfactory,butnotcritical.Aconfirmingresampleshouldbesubmitted.Additionaldiagnosticproceduresmaybeneeded toconfirmeachcondition.Correctiveactionsarenecessarytopreventreductionofservicelifeoroveralllossofperformance.
Critical Lubricantphysicalproperties,contaminationand/orcomponentwearisclearlyseriousenoughtorequireimmediatediagnosticandcorrectiveactiontopreventmajorlongtermlossofperformanceorcomponentfailureinservice. Increases inoperatinghazardare likely.Shortterm lossofperformancemayalreadybepresent. Largescalerepairsmayberequired. Itmaybenecessarytoremovetheunit/component fromserviceuntilaconfirmingresampleistestedanddiagnosticsconfirmthatrepairsarerequired.
Theseassessmentsarerelativeandareassignedusingbothtrendanalysisandcondemninglimits.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 6 -
When trendanalysis isused (as in thecaseofwearmetalsandcertaincontaminants), thresholdvaluesaredeveloped toidentifytheboundaryareabetweennormalandabnormalresults.Forwearmetals,thesethresholdvaluesvaryfordifferenttypesofcomponent,butarespecificandstableforeach individualmodelofagivenapplication.Thevaluesdonotprovidesharp linesof 'normal/abnormal' interpretations; instead, they indicate rangesof increased likelihood thataproblemhasdevelopedtoaparticularpoint.Generally,thelubricantandcomponentconditioncanbeconsidered'normal'aslongasthewearmetal,contaminationand lubricantdeterioration levelsremainwithintheestablished normal'ranges.Regardlessofthethresholdvalues,however,anysharpincrease inwearmetalsormajorshift inphysicalpropertiescansignalbeginningproblems. Therefore, the threshold values cannot be used as 'go/nogo' criteria. A great deal of caution, judgment,experienceandcustomerinputmustbeusedinapplyingthresholdvaluesproperly.
Customers are contacted immediatelyby telephoneon all sampleswhereour interpretationdetects a critical condition.Further,computergeneratedfaxand/oremailcopiesofallcriticalorabnormalsamplesaredispatcheduponcompletionofour evaluation.On these reports the labwill recommend specificmaintenance actionsdesigned to correct not only theindicatedproblemsbutalsothecausesoftheseproblems.
Whenmanycomponentsareinvolvedinyouranalysisprogram,aspreadsheetledgersystemishelpfulinsummarizingeachcomponent'soilanalysisstatus.Thecolumnsshouldrecorddateofsamplingforeachcompartment, andseparateincomingreports by the overall sample status. If you sample at the same time that you perform other routinemaintenance andservicing activities, you should record this information and submit itwith the sample. Many oil analysismanagementapplications,suchasAnalystsOnlineandLOAMSsystems,automaticallyformatoilanalysisdatainthislayout.
Eachreport
should
be
read
as
soon
as
possible.
Copies
of
the
analysis
should
be
attached
to
any
work
orders
or
instructions.
8. Provideproperfeedback.
The interpretationguidelines'accuracy isverifiedbycomparingthe labtestresultbasedpredictionswithactualconditionsconfirmedby inspection. In thisway, the test interpretations are continually refined bypracticalexperience. "Feedback"fromthecustomerincludes:
Abnormallubricantorcomponentconditionsthatyoususpectarepresent
Thefindingsofanyinspectionperformedasaresultofoilanalysisprogramrecommendations
Abnormallubricantorcomponentconditionsdiscoveredthatwerenotpreviouslyindicatedbyoilanalysis
Notificationofservicingandmaintenanceperformed
Informationconcerningoperatingenvironmentorequipmentapplicationchanges
Theseitemsmaybenotedonthesampleinformationform,recordedonacopyofthepreviousanalysisreport,ordetailedonaseparatereportsheet.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 7 -
9. Measurecosteffectiveness.
The economic goals of reducing operating expenses and increasing profitmargins have not changed sinceAnalystswasfounded. Routine oil analysis will help you achieve substantial savings inmaintenance and repair costs. The programoperatesmuchlikeamedicalcheckup;ifproblemsaredetected,theycanbecorrectedbeforetheydevelopintoseriousand
hazardousconditions
that
are
costly
to
repair.
When
samples
are
reported
normal,
then
the
immediate
value
of
oil
analysis
is
apersonal 'peaceofmind'ratherthananeconomicreturn.Asthenumberofsampledpiecesofequipment increases,thefinancialbenefitofoil analysis also increases.Greaterequipment availability and reliabilitymeansmoreproduction, lessdowntimeandincreasedprofits.
The importanceof tracking the savings generatedby youroilanalysisprogram cannotbeoveremphasized. Manpower,partsandtoolexpenseswillallbeaffected. However,becauseawellrunoilanalysisprogram isdeeply integrated intoacustomers overall maintenance program, management must establish a strong platform of results measurement anddocumentationtoseeoilanalysissuniquecontribution.
Althoughsomebenefitsofoilanalysismaynotshowclearlyonthe'bottomline'becausetheyrepresentabnormalitiesthatwereprevented,mostoftheeconomicsavingsfromoilanalysiscanbecalculatedbycomparing
Partsandlaborexpensesforcomponentrepair,overhaul,orreplacement
Lossof
revenue
during
downtime
...beforeoilanalysiswiththesamecostfactors(plustheanalysisexpenses)aftertheprogramhasbeenestablishedandby
estimatingthe
Extensionoftheaveragecomponentoperatinglifespanbeforeoverhaulorreplacement
Reductioninconsumableitemssuchaslubricantsoffuels
Increaseinproductivity
...fortheoverallgroupofunits/componentsthatyouhaveplacedonaroutineoilanalysisprogram.
FIVEKEYSTOSUCCESSFULOILANALYSIS
Aswithanydiagnosticmethod,theusermustshareintheresponsibilityforsuccesswhenusingthiswellestablishedandwidelyacceptedproactivemaintenancetool.Toachieveoverallsuccessforyouroilanalysisprogram,usetheseprovenkeys:
1. Clearlydefinedcustomergoalsandprogramrequirementsensurethatthetestsperformedfittheapplicationandthattheserviceisbeingfullyutilizedonanongoingbasis.
2. Representativesamplesensurethatthetrueconditionofthelubricantandcomponentcanbedeterminedbyreliable,accuratetesting.
3. Frequentlabcustomercontactpromotesaccurateinterpretationandleadstoincreasedcustomerconfidenceand
interestin
maintaining
an
active
oil
analysis
program.
4. CompletesampleinformationspeedsprocessingandincreasestheDataAnalysts'abilitytofullyinterpretthetestresults.
5. Rapidreportreviewensuresthatabnormalorcriticalconditionsarerecognizedandactedonintimetopreventdamageorlossofperformance.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 8 -
Withoutaworkingknowledgeofoilanalysistestsandtheirsignificance,theusermaybeuncertainaboutthevalueofthe
serviceandhoweachtest interrelateswith theotherstoprovideauseful,accuratepictureof internalcomponentand
lubricantconditions. Thefollowing information isprovidedasageneralorientationtowhatAnalystsconsidersarethe
mostimportantoilanalysistests.
SPECTROCHEMICALANALYSIS
Selected metallic elements present as microscopic particles suspended in the fluid to be analyzed are identified andmeasuredinpartspermillionbyweight.Theanalyzedelementsaregroupedintothreemaincategories:
1. Wearmetals
Relativemotionbetweenlubricatedpartsisalwaysaccompaniedbyfrictionbetweentheopposingpartsurfaces.Despitethefactthatthesesurfacesareusuallycoatedwithanoilfilm,frictionwearsthemaway.Someoftheparticlesproducedasthepartsweararesmallenoughtoremainsuspendedinthecirculatingoil.Sincethesewearproductsarecomposedofthesamematerialsasthesurfacesfromwhichtheyoriginated,the levelofeachwearmetalremaining intheusedoil indicatestherelativewearconditionofthelubricatedparts.Scientistsworkinginthefieldoftribology,thestudyofwear,stilldisagreeonhowmanyseparatekindsofwearexist.Asfewasfourandasmanyastwentyfiveclassesofwearhavebeenproposed.Fiveof
the
most
commonly
accepted
types
of
wear
are:
AdhesivewearThistypeofwearoccurswhentheoilfilmbecomessothinthattheroughestpointsoftheopposingmovingpartsurfaces
begintotoucheachother.Adhesivewearoccursnormallyduringbothbreakinandroutingserviceasthepartswearslightlytomaintain
alignment.Ifsevereadhesionoccursduetoload,speedortemperatureconditions,scuffingandscoringwillresult.Metalmaybetornoff
thepartsurfacesortransferredfromoneparttoanotherandeventualseizureoftheaffectedparts is likely.Innormalservice,adhesive
weariscontrolledwithantiwearadditives,whichcoatthelubricatedsurfacesandreducedirectparttopartcontact.
AbrasivewearAbrasivewear isacuttingorscratchingactioncausedwheneitherhardparticlesorhardprojectionswearaway softer
surfaces.Sourcesofabrasiveparticles identifiedbyoilanalysis includecontaminantssuchasdirtenteringacomponentoilsystemand
metalparticlesformedduringwear.
Fatiguewear Fatiguewear occurswhen cyclicor repeated load stresses cause cracking, spalling, and pitting of the componentpart
surfaces.Thistypeofwear ismorecommonlyassociatedwithrollingelementbearingsandgearswherethepartsurfacesrollpasteach
other.
Corrosive(chemical)wearCorrosiveorchemicalwearresultswhenchemicalreactionscausecorrosionoroxidationofpartsurfacesand
partmovementorfluidpressuredislodgesmaterialfromthissurfacelayer.Thistypeofwearisassociatedwithrustpromotingconditions,
corrosivecontaminantsandexcessivelyhighlevelsofchemicallyactiveadditives.
CavitationwearCavitationwearoccurswhenmetal is removed frompartsby the impactofcollapsingcavitationbubbleson thepart
surfaces.Cavitation itself is associatedwithpartial vacuums formed ina liquidby sudden changes inpressure andmaybe causedby
vibration,reducedorunevenliquidflowandotherfactorsinvolvingparticularcomponentpartshapesandmovements.
2. Contaminants
Dependingupon the circumstances,manydifferent substancesmaybe classifiedas contaminants. Silicon, in the formofsilicon dioxide (sand), is one of themost common contaminantsmonitoredwith spectrochemical analysis. Similarly, the
presence
of
grease
contaminating
an
oil
system
may
be
indicated
by
increases
in
aluminum
or
barium
if
the
grease
contains
metallicsoaps.Althoughcontamination iscommonlyassociatedwithsubstancesenteringacomponent'soilsystemfromanoutsidesource,wearmetalsthemselvesarealsoaformofcontaminant.
3.Additives
Additivesarechemicalcompoundsaddedtooils,fuels,andcoolantsto impartspecificbeneficialpropertiestothefinishedproducts. Additives create new fluid properties, enhance properties already present and reduce the rate at whichundesirablechangestakeplaceinafluidduringservice.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 9 -
WEARMETALSANDCONTAMINANTS
SILICONSilicon istypicallyassociatedwithdirtcontamination. Thiscontaminationcanresultfromanyconditionthatallowsdirt toenteracomponentoilsystem.Othersourcesofsiliconincludeseals,oilandcoolantadditivesandgreases.
IRONandalloysReciprocatingengine:Gearsandshafts;block;cylinderliners;valvetrain;connectingrods,ringsandoilpump;some
bearings;somepistons;someaccessorysystems.
Turbineengine:Gearsandshafts;bearings;pumps;housings.
Transmission: Gearsandshafts;bearings;brakesanddisks;pumpsandshiftspools;PTO;housing.
Torqueconverter:Shafts;bearings;somehousings.
Differential: Shaftsandgears;bearings;housing.
Transaxle/finaldrive/reductiongearbox:Gearsandshafts;bearings;housing.
Hydraulic: Rotors,vanes,pistons,androds;housingandbores;gearsandshafts;valves.
Reciprocating and rotary compressors: Gears and shafts; case; valves; cylinder liners; crossheads; rings and screws or
turbines;bearings;someoilcoolertubing.
COPPERandalloysReciprocatingengine:Bearings;wristpinandvalvetrainbushings;otherbushingsandthrustwashers;oilcoolertubing.Also
maybepresentasanoiladditiveoracrossovercontaminantfromaleakingtransmissionseal.
Turbineengine:
Some
main
and
accessory
bearing
retainers;
bushings
and
nuts;
some
oil
control
valves.
Transmission: Discs;bearings;bushingsandthrustwashers;oilcoolertubing.
Torqueconverter:Retainersandseparators.
Differential: Bearings;bushings,retainers,andthrustwashers.
Finaldrive/reductiongearbox: Bearings;bushings,retainers,andthrustwashers;oilcoolertubing.
Hydraulic: Bearingsandbushings;swashplatecups;valves;somepistons;somepumpcylinders;oilcoolertubing.
Reciprocatingandrotarycompressors:Bearings;bushings,thrustwashersandretainers;oilcoolertubing.
ALUMINUMandalloysAllcomponents:Aluminumoxidespresentintheenvironment,typicallyassociatedwithsilicon(dirt)contamination.
Reciprocatingengine:Pistons;bearings;bushings;blocks,mainandaccessorycasesandhousings;someoilcoolertubing.
Turbineengine:Mainandaccessorycase,housings;someretainers;seals;baffles.
Transmission: Somecases;bushingsandretainers.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 10 -
ALUMINUMandalloys(contd)Torqueconverter:Impellers.
Differential: Bushingsandthrustwashers.
Final
drive/reduction
gearbox:
Bushings
and
thrust
washers.
Hydraulic: Somepumphousings.
Reciprocatingandrotarycompressors:Case;impellers,somepistonsandcrossheads;retainers.
CHROMIUMalloyandplatingReciprocatingengines:Linersandrings;shafts;valvetrain.
Turbineengine:Bearings;shaftsandgears;seals.
Gearedcomponents(general):Bearings;shafts;seals.
Hydraulic:Rods;valves.
Reciprocatingandrotarycompressors:Linersandrings;shafts;valvetrain.
LEADandTINoverlayorflashingReciprocatingengine:Bearings;somepistons;bushingsandthrustwashers.
Finaldrive/reductiongearbox:Bearings;bushings.
Hydraulic: Pumpthrustplate;bushings.
Reciprocatingandrotarycompressors:Bearings;bushings.
Theuseofleadasanextremepressure(EP)oiladditivehasbeenbanned.
Tinmaybepresentasanoiladditive,usuallyinconjunctionwithlubricantscontainingmolybdenumcompounds.
NICKELalloy(withiron);platingReciprocatingengine:Gearsandshafts;valvetrain;bearings.
Turbineengine:Gearsandshafts;bearings.
Gearedcomponents(general):Gearsandshafts;bearings.
Hydraulic:Gears
and
shafts,
bearings.
SILVERplating;tracerGeneral: Somebearingsandbushings;oilcoolersolder;seals.
Silverisalsooccasionallyusedasaphysical'tracer'toindicatethatwearhasprogressedtoacertainpoint.Inthisapplication,
silveriseitherplateddirectlyontoapartsurfaceorincorporatedintoalayerunderthesurface.Thewearconditionofthe
partcanthenberelatedtotheamountofthetracerdepositedintheoil. Thisusageismostoftenfoundinaerospace
applications.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 11 -
MOLYBDENUMalloy(withiron);plating
General: Somebearings;somepistonrings.
MAGNESIUMalloy
General: Casesandhousings.
TITANIUMalloy(withiron)
General:Some shafts,bearings,and gears.Typically foundonly in certain aerospace and heavy commercial or industrial
applications.
ANTIMONYalloy(withleadand/ortin)
General:Certaintypesofjournalbearingoverlays.
ZINCalloy
General:Brassfittings(withcopper);galvanizedsurfaces.
ADDITIVES
Most
modern
lubricants
and
coolants
contain
organometallic
oil
additives.
Some
of
these
additives
are
formed
from
compoundsofoneormoreofthesamechemicalelementsusedincomponentparts.
MOLYBDENUM
Extremepressureadditiveinspecialtyoilsandgreases;corrosioninhibitorinsomecoolantsupplemental additives.
MAGNESIUM
Detergent,dispersant,alkalinityincreaser.
SODIUM
Corrosioninhibitorinoilsandcoolants.
BORON
Detergent,dispersant;antioxidantinoilsandcoolants.
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 12 -
BARIUM
Corrosionandrustinhibitors;detergent;antismokeadditiveinfuels.
PHOSPHORUS
Antiwear;combustionchamberdepositreducer;corrosioninhibitorincoolants.
POTASSIUMCompounds
Corrosioninhibitor;traceelementinfuels;alsofoundasamineralsaltinseawater.
CALCIUM
Detergent,dispersant,alkalinityincreaser.
ZINC
Antiwear,antioxidant,corrosioninhibitor.
ANTIMONY
Antiwear,antioxidant.
PHYSICAL
ANALYSIS
VISCOSITY
Viscosity isa lubricant's internalresistancetoflowatagiven temperature inrelation totime,and isconsideredtobethesingle most important physical property of a lubricant. Changes in viscosity indicate improper servicing, dilution,contaminationorlubricantbreakdowninservice.Viscosityisusuallydeterminedwithakinematicmethodandtheresultsarereportedincentistokes(cSt)*.Inadditiontotheviscosityresult,thecrankcaseoilviscosityclassofanenginelubricantmayalsobeexpressedasanSAEGrade.
*1Centistoke(cSt)=1squaremillimeterpersecond
WATER
Thepresence ofwater in anonwaterbase fluid indicates contamination from an outside source or from condensation.
Excessive
levels
of
water
promote
lubricant
breakdown
and
component
part
corrosion.
Results
are
reported
in
percent
(%)
volume.
Incertaincomponentsandapplications wherewatercontamination mustbekeptextremely low,theKarlFischer titrationmethodisusedtomeasureandreportwatercontentinpartspermillion(ppm).
FUELSOOTbyLEM
LEM is the acronym for Light ExtinctionMeasurement, an Analysts, Inc. patented process to determine fuel soot. LEM
measuresthefuelsootdispersedintheoilofdieselengines.Thisisanindicationofthecombustionefficiencyoftheengine.
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BASICSOFOILANALYSIS
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Anexcessiveconcentrationofsootallows theoil togel, formingsludge in theengine, leading topooroilcirculation. It isaffectedby fuel injectorefficiency, injector timing, integrityof the ringpiston seal,oil consumption and the loadon theengine.Resultsarereportedinweightpercent(%).LEMisthemostefficientandaccuratemethodtomeasurefuelsoot.
FUELDILUTION
Fueldilution
indicates
the
relative
amount
of
unburned
diesel
fuel
or
gasoline
present
in
an
engine
lubricant.
This
dilution
is
associatedwithimproperlyadjustedormalfunctioningfuelsystemassemblies.Excessivefueldilutionlowerslubricantloadcarryingcapacities,promoteslubricantbreakdownandincreasestheriskoffireorexplosion.Fueldilutionisdeterminedbygaschromatography andisreportedinpercent(%)volume.
GLYCOL
Positive testresults indicate thepresenceofethyleneglycol,mostcommonlyassociatedwithcoolingsystem leaks.Glycolcontaminationpromoteswear,corrosion,sludging,andlubricantbreakdown.Iftheanalysisindicatesthatcoolantadditivesor water contamination is present in the oil sample, additional chemical tests are used to confirm ethylene glycolcontamination.
INFRAREDANALYSIS
Whenan
organic
compound,
such
as
lubricating
oil,
is
exposed
to
infrared
light,
the
substances
present
in
the
compound
will
absorbthelightatspecificwavelengths.Theamountofabsorbanceataparticularwavelengthisrelatedtoboththetypeandquantity of absorbingmaterial.When the infrared absorbance spectrum of an unused oil provided by the customer iscomparedtothespectrumofthesametypeofused lubricant,certaincontaminantsandphysicalchanges in the lubricantcan be directly measured. Although infrared analysis can detect and measure an extremely wide range of organiccompounds,itismostfrequentlyusedinoilanalysistomonitor:
FuelSoot
The amount of fuel soot carbon suspended in the engine lubricant.Higher values indicate reduced combustionefficiencyduetosuchconditionsasairintakeorexhaustrestrictions,injectormalfunctionsorexcessiveidling.Testresultsarereportedonanabsorbancescale.
Oxidation
Thechemical
incorporation
of
oxygen
into
and
subsequent
loss
of
lubricant
performance
due
to
aging,
adverse
or
abnormaloperatingconditionsorinternaloverheating.Testresultsarereportedonanabsorbancescale.
Nitration
Theorganicnitratesformedwhencombustionbyproductsentertheengineoilduringnormalserviceorasaresultofabnormal'blowby'pastthecompressionrings.Testresultsarereportedonanabsorbancescale.
Water
Watercontamination producesacharacteristicpeak inmostoils,whichcanbeeasilymeasured. Testresultsarereportedin%volume.
Glycol(coolant)contamination, sulfates,andcertainadditivesmayalsobemonitoredusinginfraredanalysis.
NOTE:Thedeterminationofoxidationrequiresasampleofnewoilforaninstrumentandinterpretationreference.
NEUTRALIZATIONNUMBER
Boththeacidcontentandthealkalinecontentofalubricantmaybemeasuredandexpressedasaneutralizationnumber:
TotalAcidNumber(TAN)
Measuresthetotalamountofacidicmaterialpresentinthelubricant.Generally,an increase inTANabovethatofthenewproductindicatesoiloxidationorcontamination withanacidicproduct.Theresultsareexpressedasa
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BASICSOFOILANALYSIS
Form 4015.2 (BasicsOA.pdf 9/08) 2008 Analysts, Inc. - 14 -
numericvaluecorrespondingtotheamountofthealkalinechemicalpotassiumhydroxiderequiredtoneutralizetheacidinonegramofsample.
TotalBaseNumber(TBN)
Measuresthetotalalkalinecontentpresentinthelubricant.Manyoftheadditivesnowusedinengineoilscontain
alkaline
(basic)
materials
intended
to
neutralize
the
acidic
products
of
combustion.
A
relatively
high
TBN
is
associatedwith increased protection against ring and cylinder liner corrosion. Abnormal decreases in TBNmayindicatereducedacidneutralizingcapacityoradepletedadditivepackage.Thetestfirstdeterminestheamountofacidrequiredtoneutralize thealkalinecontentof thesample.Thefinalresult isthenexpressedasanequivalentamountofpotassiumhydroxideinonegramofsample.
SOLIDS,WEIGHTbymembranefiltration
Solidscontentinanoilsamplemayalsobemeasuredbyweight.Thetestdeterminestheamountoffilterablesolidmaterialin the samplewithparticlesizesgreater than the filterpore sizespecified for the test.The test isperformedbyvacuumfiltrationand theresult isreportedasanumericvalue.Theresultmaybeexpressedeitherasaweightpercentagewhichcomparestheweightoftheliquidsampletotheweightofthesolidmaterialinit,orastheactualweightofthesolidmaterialinaspecifiedvolumeofsample.
AUTOMATEDPARTICLE
COUNT
Thisinstrumentusesaspecialdetectorwhichcountsandsizesparticlespresentinthefluid.Resultsarereportedasnumbersofparticlesinaspecificsizerangeperagivenvolumeofsample.
Thesizerangesandreportingmethodsare inworldwidetransitionduetocalibrationandprocedurechanges,andawellknown aerospace standard (NAS 1638) is being retired in favor of a related andmoremodern SAE standard. The newstandards and ranges have been carefully researched and selected for maximum accuracy and minimum impact onpreviouslyestablishedparticlecountguidelines.
Threesize rangesrepresent the ISO4406standard:>4microns (changed from>2microns),>6microns (changed from>5microns)and>14microns(changedfrom>15microns).SixsizerangesrepresenttheSAEAS4059standard: thethree ISOranges previously noted, plus three additional ranges >21 microns, >38 microns, and >70 microns (changed from >25microns,>50microns,and>100microns).
ResultsfromtheparticlecountarethenusedtodeterminefluidcleanlinessviaISOorSAEclassificationcodes.TheISOClasscode is expressed as three separate numbers (for example, 20/15/12). The first number represents the relativecontaminationlevelfromthefirstsizerange,andthesecondandthirdrangesaresimilarlycalculated. TheSAEClasscodehasseparatesizerangelimitsforeachofthesixparticlesizes,butthecodeisgenerallyexpressedasthesinglehighestlimitreachedwithinanyofthesixclasses(forexample,SAEClass5).
Abnormal particle contamination levels are associatedwith increasedwear, operational problems,with close tolerancecomponents,fluidcontaminationordegradationandlossoffilterefficiency.
DIELECTRICSTRENGTH
This testmeasures an oil's ability towithstand an electric currentwithout failing.Oil is placed in the gap between two
electrodesand
an
increasingly
higher
voltage
is
applied
to
the
oil
until
an
arc
forms
across
the
gap.
In
large
transformers,
the
circulatingoil isformulatedtoactasan insulator.Therelative insulatingcapacityofthetransformeroil is indicatedbythedielectricstrength.Generally,smallamountsofwater,dirt,ormetalwillaffectthetestresult.Forthisreason,thedielectricprinciple forms theworking basis formany differentmodels of fieldtest type oil analyzers. Results are reported in kV(kilovolts).
FERROGRAPHY
Ferrography isananalytical technique inwhichwearmetalsandcontaminantparticlesaremagneticallyseparated fromalubricant and arranged according to size and composition for further examination. It is widely used in oil analysis todeterminecomponentconditionthroughdirectexaminationofwearmetalparticles.
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BASICSOFOILANALYSIS
Form 4015 2 (BasicsOA pdf 9/08) 2008 Analysts Inc 15
Therearethreestagesinacompleteferrographicanalysis:(1)directreading(DR)ferrography,(2)analyticalferrographyand(3)theferrograminterpretationandreport.
DR(directreading)ferrographyprecipitatesthewearparticlesfromasampleandelectronicallydeterminesthequantityof'large' (over5microns)and 'small' (1 to2microns)particlespresent in thesample.Wearcalculations from these resultsindicatetherate,intensityandseverityofwearoccurringinthesampledmachine.IncaseswheretheDRferrographyweartrends
indicate
an
abnormal
or
critical
wear
condition,
analytical
ferrography
can
reveal
the
specific
wear
type
and
probable
sourceofthewearcondition.
Analytical ferrography uses the Ferrograph Fluid Analyzer to concentrate on directmicroscopic evaluation of thewearparticles.Aferrogramslideispreparedbydrawingtheoilsampleacrossatransparentglassorplasticplateinthepresenceofastrongmagneticfield.Wearparticlesarepulledtoandsortedontheplateinamannersimilartothatused inthedirectreadingferrograph.Afterdeposition,theoiliswashedaway,leavingtheparticlesclean,alignedwiththemagneticfield,andfixedtotheplate.Anexperiencedevaluatorthenexaminestheferrogramtodeterminethecompositionandsourcesoftheparticlesandthetypeofwearpresent.
TheDRferrographyreportincludesspectrochemicalanalysis,largeandsmallparticlequantityindexes,andtheresultsfromwear rate, intensity and severity calculations. An analytical ferrography report includes specific type and quantityclassificationsof themetallicandnonmetallicdebrispresenton theslide,acolorphotomicrographof the ferrogram,anassessmentofthesampledmachine'soverallwearstatusandadetailedinterpretationoftheferrographyresults.